BOUNDARY FILL

The Boundary Fill function, as illustrated in Figure 6.1.64 includes INNER FILL, OUTER SMOOTH, SIDE STEP, and DOUBLE FILL.

Figure 6.1.64  Boundary fill

 

6.1.4.1  INNER FILL

The INNER FILL function is used to fill holes and missing geometry on outer boundary of the parts such as windows, wheel houses, tail light lamps, access holes, bolt holes, etc. as illustrated in Figure 6.1.64.

 

CREATE SURFACE

This option allows user to decide if surfaces are generated upon completion of the inner fill operation.

 

USE REFERENCE LINE

It is an advanced option. For filling complicated surface, the user can create some reference curves to fill the holes.

 

KEEP TANGENT

This option enables the user to keep tangency between the existed surfaces and surfaces generated by fill operation. Figure 6.1.65 illustrates the surface generated with and without tangency option.

 

Figure 6.1.65  Toggle on/off Keep Tangent option

 

ADVANCED

The advanced option includes some auxiliary functions that are mainly applied on single hole fill, as shown in Figure 6.1.66. These functions are used for generation of reference lines, removal of curves, surfaces and elements. Detailed description about these functions refers to Section 5.2.11  Surface Split.

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Figure 6.1.66  Advanced option

 

DELETE

This option enables the user to remove the selected entities from the database.

 

MORPH HOLE FILL

This function enables the user to edit the filled hole by adding control lines. Clicking this button, the program pops up a dialog box illustrated in Figure 6.1.67. The user can toggle on TANGENT option to keep tangency between the generated surface boundary after editing and the part. The user can click ADD, EDIT or REMOVE button to add, edit or delete control lines, and click PREVIEW to preview the generated part hole surface after editing. The operations of this dialog box are similar to the one described in Section 6.2.3 Modify Binder.

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Figure 6.1.67  Morph hole surface

 

There are four functions available in INNER FILL dialog box: AUTO FILL, HOLE FILL, CURVE FILL and POLYGON FILL.

 

TO PART

The user must specify a part prior to hole fill. The user may directly input a part name or click SELECT PART button to select a created part.

 

l  AUTO FILL

 

After selecting this button and clicking APPLY, the program will automatically find all the inner holes and highlight their boundaries, as shown in Figure 6.1.68.

Figure 6.1.68  Before Inner Fill

Simultaneously, eta/DYNAFORM prompts:

 

CLICK ON INNER BOUNDARYS TO DE-SELECT

MIDDLE BUTTON – DONE, RIGHT BUTTON - CANCEL

If there are holes which do not need to be filled, the user can select them by mouse cursor and click on the middle mouse button to confirm. The result is shown in Figure 6.1.69.

Figure 6.1.69  After Inner Fill

 

UNDO

If the user is not satisfied with the result of Auto Fill, he/she can select UNDO button to cancel this result.

 

EXIT

Exit the Inner Fill interface.

 

l  HOLE FILL

This function allows the user to fill holes individually. Once this function is selected, the boundary of the inner hole on the current screen is highlighted. Then, the program prompts the user to select an inner boundary to be filled by using the left mouse button. After an inner boundary is selected, the program will automatically fill the hole, as illustrated in Figure 6.1.70.

Figure 6.1.70  Boundary Lines of Inner Holes

 

If Hole Fill function is selected, User Reference Line option is activated for the user to create some reference lines for hole filling, as illustrated in Figure 6.1.71.

Figure 6.1.71  Filled Mesh within a Closed Curve

 

l  CURVE FILL

This function allows the user to fill a cut-out area. Click APPLY to highlight all the boundaries. The program will prompt:

SELECT A BOUNDARY TO FILL

 

Use the left part to select a point on the boundary line to be filled. The program prompts:

 

SELECT A LINE TO CLOSE THE OPEN AREA

 

Select an existing line as the outer boundary to finish filling.

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Figure 6.1.72  Before curve fill

 

34

Figure 6.1.73  After curve fill

Figure 6.1.72 and Figure 6.1.73 show the filling process in an open area using spline curve.

 

l  POLYGON FILL

This function allows the user to select a set of nodes as the boundary edge to create a mesh to fill the boundary. After function is selected, the SELECT NODES dialog box is displayed. The following message is printed in the message prompt window:

 

SELECT A SET OF NODES IN SEQUENCE ALONG THE BOUNDARY

 

After a set of nodes is selected, eta/DYNAFORM will generate a set of elements to fill the inner boundary.

 

6.1.4.2  OUTER SMOOTH

The functions provided in the OUTER SMOOTH dialog box are used to smooth the outer boundary of the selected part. Before outer smooth, the user must specify a part by clicking on SELECT PART button. As illustrated in Figure 6.1.74, there are four functions in the dialog box:

 

1.  ROLLER

2.  MORPHING

3.  CORNER SMOOTH

4.  EXPAND

Figure 6.1.74  Outer Smooth

 

TO PART

The user must specify a part for outer smooth. The user may directly input a part name or click SELECT PART button to select a created part.

 

l  ROLLER

    This function allows the user to roll a cylinder with a defined radius along the boundary and fill the gaps between the part boundary and the cylinder.  Once this function is selected, a dialog box as illustrated in Figure 6.1.75 is displayed.  The default radius of the cylinder is 300 (mm) in the ROLL RADIUS input field.

Figure 6.1.75  Roller dialog box

 

1.       After the desired radius is entered, click on the CREATE BOUNDARY button to show the new boundary line with the cylinder rolled along the part boundary.  If the result is acceptable, click on the FILL BOUNDARY button to fill the gap with elements and new surface. A new part will be created to include the elements and surfaces. The part will be automatically assigned as the DIE.

2.       The UNDO function is used to remove the filled mesh in the gap and allow the user to go back to the original part. Figure 6.1.76 illustrates the result of a typical roller operation.

roller1    roller2

Figure 6.1.76  An illustration of a roller operation

3.       Click on the EXIT button to exit the function.

 

LOCAL SMOOTH

This option allows the user to smooth the local boundary using a cylinder with a defined radius along a selected boundary, as illustrated in Figure 6.1.77.

99

Figure 6.1.77  Local smooth

 

KEEP TANGENT

This option enables the user to keep tangency between the existed surfaces as meshes and surfaces as well as meshes generated by smooth operation.

 

CREATE BOUNDARY

Clicking this button after specifying the radius, the program will highlight the part boundary and prompt the user to show the first point on boundary line in the message prompt window. After the first point is selected, the user is prompted to select the second point and click the middle mouse button to confirm.

 

EDIT END-POINT

This function allows the user to edit boundary point. As illustrated in Figure 6.1.78, this button is activated after the boundary of smooth area is created. Click this button to highlight the boundary points. The user may move the boundary points using cursor to edit the position of boundary points.

105

Figure 6.1.78  Edit local smooth

 

EDIT BOUNDARY

This function enables the user to edit the created boundary line. This button is activated after the smooth boundary is created. Click this button to show all the points on the boundary line and prompts:

 

SELECT TWO POINTS ON LINE TO DEFINE EDIT REGION

 

After selecting two points on the boundary line, the program pops up the CURVE EDIT window illustrated in Figure 6.1.79. Refer to Section 5.1.15 for detailed description about related operations.

37

Figure 6.1.79  Edit boundary

 

FILL BOUNDARY

If the smooth result is acceptable, click on the FILL BOUNDARY button to fill meshes and generate surfaces between the new boundary and the original boundary. Edit the boundary points after filling. The Edit Boundary and Fill Boundary are disabled, as illustrated in Figure 6.1.80.

106

Figure 6.1.80  Local smooth

 

EDIT FILLED SURFACE

This function is used to edit the local smoothed result by adding control lines. Clicking this button, the program pops up a dialog box illustrated in Figure 6.1.81. Click ADD, EDIT or REMOVE button to add, edit or delete control lines, and click APPLY button to regenerate local smoothed surface. The operation of this dialog box is similar to the one in Section 6.2.3 Modify Binder.

38

Figure 6.1.81  Edit Filled Surface

 

Figure 6.1.82 illustrates the result of a typical roller operation using the LOCAL SMOOTH option.

39

Figure 6.1.82  Local smooth result

l  MORPHING

This function allows the user to locally modify the part mesh by morphing the boundary line of the part. Figure 6.1.83 illustrates dialog box of the MORPHING function.

Figure 6.1.83  Morphing dialog box

1.       Click on the MORPHING BOUNDARY button to highlight the boundary of the part. Eta/DYNAFORM requests the user to select two points on the part boundary to define a morphing region. Figure 6.1.84 illustrates the selected region on the part boundary for morphing operation.

Figure 6.1.84  Select Morphing Boundary

2.       After two points are selected, the CURVE EDIT dialog box as illustrated in Figure 6.1.85 is displayed. About the detailed description of Curve Edit function, the user can refer to the Section 5.1.15.

41

Figure 6.1.85  Curve Edit dialog box

3.       Click on the FILL BOUNDARY button to fill elements between the original boundary and the smoothed boundary.  The result from a typical morphing operation is illustrated in Figure 6.1.86.

 

  

 

Figure 6.1.86  Morphing Result

 

4.       The UNDO button is used to remove the elements from the gap, allowing the user to return to the original boundary and keep the newly created part in IGS_SMH.  PART NAME enables the user to assign a name to the part; it will be automatically assigned as TOOL.

 

5.       Click on the EXIT button to exit the function. The generated elements, nodes or surfaces, etc. will be automatically saved in a part named IGS_SMH. The user can modify the name of this part and the generated part will be automatically added to the punch.

 

l  CORNER SMOOTH

This function allows the user to smooth sharp corners on a part using a defined radius. eta/DYNAFORM will generate a set of elements in circular shape with the defined radius around the selected point.

When this function is selected, the dialog box as illustrated in Figure 6.1.87 is displayed.  The default corner radius is 30 (mm) as displayed in the input field of CORNER RADIUS.

 

Figure 6.1.87  Corner Smooth dialog box

1.       After entering the desired corner radius, click on the CORNER SMOOTH button to highlight the boundary line of the part such as illustrated in Figure 6.1.88.

Figure 6.1.88  Sharp Corner

2.       The user selects a node on the boundary for the corner smooth operation.

3.       After a node is selected at a sharp corner, eta/DYNAFORM will generate a set of elements around the part boundary to create a circular shape to smooth the edge.  Figure 6.1.89 illustrates a typical result of a corner smooth operation.

 

Figure 6.1.89  Corner Smooth

 

4.       The UNDO button is used to remove the elements from the smoothed corner and allowing the user to obtain the original boundary.

5.       Click on the CLOSE button to exit the function.

 

 

l  EXPAND

 

The EXPAND function is used to extend the part boundary with elements using approximate 3mm formable radius.  When this function is selected, dialog box as illustrated in Figure 6.1.90 is displayed.  The value in the input field of EXTENSION is the default extension value for the active part.  The user can type in any positive value.

Figure 6.1.90  Boundary Expand dialog box

 

1.       Click on the BOUNDARY EXPAND button to highlight the boundary of extension as illustrated in Figure 6.1.91(a).  The default extension value is calculated from the average element size.  The user can input other value following by clicking the BOUNDARY EXPAND button once again to modify the default value.

2.       Select the MORPH BOUNDARY button to morph the boundary line. Refer to Section 5.1.15 LINE MORPHING for description of this function.

3.       The FLATTEN BOUNDARY SEGMENT function allows the user to flatten line segment between two selected points on the boundary line.

(a) Extended boundary                             (b) Filling extended boundary

Figure 6.1.91  An illustration of the Boundary Expand operation

 

4.       When the morphed boundary is accepted, click on the FILL BOUNDARY button to generate the mesh between the original boundary and the extension boundary.  An illustration of extended boundary with filled elements is illustrated in Figure 6.1.91(b).

5.       The SMOOTH CORNER function allows the user to smooth a selected a sharp corner.

 

NOTE:  A sharp angle is determined by two adjacent boundary elements when the angle between two boundary edges is greater than 30º.

6.       Click on the UNDO button to remove the generated mesh and exit the function.

 

6.1.4.3  DOUBLE FILL

This function is used to fill the gap of double attach, as illustrated in Figure 6.1.92. After the LEFT PART and RIGHT PART are defined in Double Attach page, DOUBLE FILL page is enabled. Clicking APPLY button, the program will automatically generate outline and control lines between two parts according to the different types of double attach.

Figure 6.1.92  Double fill

 

l   ADJUST BOUNDARY POINT

Click this button to adjust the position of boundary point in order to determine the region to be filled. For LEFT/RIGHT HALF/FULL INPUT, adjust the two boundary points of one side and the boundary points of the other side will be symmetrically adjusted simultaneously, as illustrated in Figure 6.1.93. For TWO PARTS, the user needs to adjust four boundary points respectively, as illustrated in Figure 6.1.94.

46

Figure 6.1.93  Highlight two boundary points

 

47

Figure 6.1.94  Highlight four boundary points

 

l   CONTROL LINE

The program automatically generates some key control lines, adds them to the control line list and marks them with serial numbers in the display area, as illustrated in Figure 6.1.95.

Figure 6.1.95  Control lines

 

l   LINE TANGENT

The program provides two methods to define the direction of control lines, as illustrated in Figure 6.1.96.

line tangent

Figure 6.1.96  Line Tangent

 

1.  BY REFERENCE LINE

Select a reference control line and then select other control lines. The selected control lines will use the direction of the reference line as their directions.

 

As illustrated in Figure 6.1.97 and Figure 6.1.98, select control line 6 as the reference control line first. Then select the control line 5 to change its direction and show the changing result.

49

Figure 6.1.97  Select reference control line

50

Figure 6.1.98  Change the direction of control line 5

 

2.  USER DEFINE

This function allows the user to define the direction of control lines by defining vector. After selecting a control line, a Vector dialog box illustrated in Figure 6.1.99 appears. Refer to Section 5.1.4 Shortest Curve for detailed description about defining vector.

21

Figure 6.1.99  Vector dialog box

 

l   MODIFY LINE POSITION

Clicking this button, the program prompts the user to select a control line. Put the cursor on the filling boundary to select a position point. The program will automatically move the select control line to the point.

 

For LEFT/RIGHT HALF/FULL INPUT, the user only needs to select one position point on one side of the boundary, and the point on the other side will be calculated automatically.

For TWO PARTS, the user needs to select two position points on the two sides of boundary.

 

l   ADD

The user may add control lines on the part boundary.

 

l   DELETE

Click this button and select the control lines to be deleted in the display area. Click the left mouse button to delete.

 

l   EDIT

Click this button and select a control line. The Curve Edit dialog box illustrated in Figure 6.1.100 is displayed. Refer to Section 6.5.1 Edit Line for detailed description about this operation.

Curve Edit

Figure 6.1.100  Edit control line

 

l   Apply

Click this button to generate elements and surfaces in the fill region, and add these elements and surfaces to DOUBLE part.

 

l   Remove

Click this button to delete all filled elements and surfaces from DOUBLE part.

 

NOTE: For LEFT/RIGHT HALF/FULL INPUT, the filled surface is symmetric about the symmetry plane, as illustrated in Figure 6.1.101.

 

For TWO PARTS, the filled surface is not symmetric, as illustrated in Figure 6.1.102.

51

Figure 6.1.101  Symmetry fill

 

52

Figure 6.1.102  Asymmetry fill

 

6.1.4.4  SIDESTEP

This function allows the user to extend part boundary and provide side-step features. The dialog box is illustrated in Figure 6.1.103.

Figure 6.1.103  Sidestep dialog box

l  SIDESTEP MANAGER

All the created Sidesteps will be added into the Sidestep Manager list illustrated in Figure 6.1.103. The selected Sidesteps will be highlighted in the graphic display window, as illustrated in Figure 6.1.104.

54

Figure 6.1.104  Highlight the selected SideStep2

l  ADD

Click ADD button to highlight the boundary of part as illustrated in Figure 6.1.105.

55

Figure 6.1.105  Highlight the boundary of part

The following message is printed in the message prompt window:

 

SELECT TWO POINTS ON BOUNDARY TO DEFINE THE FILL REGION

SELECT FIRST POINT ON BOUNDARY

SELECT SECOND POINT ON BOUNDARY

After two points are selected to define the fill region, it prompts:

 

SELECT TWO POINTS IN MARKED REGION TO DEFINE UPPER PLANE

SELECT FIRST POINT IN MARKED REGION

SELECT SECOND POINT IN MARKED REGION

After the four points are selected, the program will automatically generate the outline of sidestep, as illustrated in Figure 6.1.106, and pop up the Sidestep dialog box illustrated in Figure 6.1.107.

56

Figure 6.1.106  Outline

57

Figure 6.1.107  Add sidestep

1.  TO PART

Specify a part for sidestep. The user may directly input a part name or click SELECT PART button 66 to select a created part.

 

2.  CONTROL LINE

After the desired region is selected, the program will automatically create UPPER PLANE-LINE, LOWER PLANE-LINE and PROFILE, as illustrated in Figure 6.1.106, and add the plane lines and profiles into the list for the user to edit, as illustrated in Figure 6.1.108.

61

Figure 6.1.108  Control line

NOTE: The user is allowed to edit plane lines but is not allowed to add and delete them. The user is allowed to add, edit and delete profiles.

 

3.  ADD

Click ADD button to add profile in the specified position.

 

4.  EDIT

This function allows the user to edit the shape of control lines. Select the plane lines or profiles to be edited in the list. Click EDIT button to display the Curve Edit dialog box illustrated in Figure 6.1.109. Edit the lower plane-line as illustrated in Figure 6.1.110.

80

Figure 6.1.109  Curve edit window

 

62

Figure 6.1.110  Edit lower plane-line

The detailed description about Curve Edit dialog box is given below:

 

X, Y, Z

Show the coordinates of the selected control point.

 

dX, dY, dZ

Show the coordinate increments of the initial position and the moved position for the selected control point in the global coordinate system..

 

CURVE

This option is enabled after selecting a line segment. If this option is toggled on, the selected straight line will change to a curve line.

 

STRAIGHT

This option is enabled after selecting a line segment. If this option is toggled on, the selected curve line will change to a straight line.

 

R

This option is enabled if both sides of the selected control point are straight lines. The user may enter the radius value by manual and press ENTER to confirm. The program will generate an arc.

 

THETA

This option is enabled if both sides of the selected control point are straight lines. It is used to define the angle of the two straight lines. The user may enter an angle value by manual and press ENTER to confirm.

 

LEN

Show the length of the selected line segment.

 

ADD PT

Click this button to add points on plane lines.

 

REMOVE PT

Click this button to remove points from plane lines by using the left button.

 

MOVE PT

Click this button, select a point by clicking the left mouse button and hold the left button to move point. Or directly move point in the display area by holding the left mouse button.

 

OK

Click this button to confirm all the settings and exit Edit window.

 

RESET

Restore the latest setup to the previous status.

 

CANCEL

Exit the Edit window without any modification of line.

 

5.  REMOVE

Allow the user to remove the selected profile.

 

6.  EDIT END-POINT

Allow the user to edit the end-point of plane lines and profiles.

 

EDIT PLANE LINE END-POINT

Select UPPER PLANE-LINE or LOWER PLANE-LINE in the control line list. Clicking this button, the program will automatically highlight the four end-points of the plane line as illustrated in Figure 6.1.111. The user may re-define the filled region by moving the end-points of plane line using mouse cursor.

 

67

Figure 6.1.111 Edit the filled region

 

EDIT PROFILE END-POINT

Select a profile from the control line list. Clicking this button, the program will automatically highlight all the end-points of the profile. The user may edit the position of end-point by moving the mouse cursor as illustrated in Figure 6.1.112.

 

64

Figure 6.1.112  Edit end-points of profile

7.  PLANE LENGTH

This function allows the user to edit the length of plane line. This function is enabled after selecting the  UPPER PLANE-LINE or LOWER PLANE-LINE in the control line list, as illustrated in Figure 6.1.113. Drag the slider bar to the desired length.

59

Figure 6.1.113  Plane length

8.  PLANE DIRECTION

This function is used to define the direction of plane lines. This function is enabled after selecting the  UPPER PLANE-LINE or LOWER PLANE-LINE in the control line list, as illustrated in Figure 6.1.114. The user may drag the slider bar to adjust the direction or select USER DEFINE option. After clicking this button, a Vector dialog box illustrated in Figure 6.1.115 appears. Refer to Section 5.1.4 Shortest Curve for detailed description about defining vector.

60

Figure 6.1.114  Plane direction

38

Figure 6.1.115  Define direction vector

After finishing the editing, click APPLY button to generate sidestep as illustrated in Figure 6.1.116.

 

65

Figure 6.1.116  Generate sidestep

l  EDIT SIDESTEP

This function is used to edit the created sidestep. Select the desired sidestep in the list and click EDIT button to re-edit all the parameters for sidestep in the dialog box illustrated in Figure 6.1.107.

 

l  DELETE SIDESTEP

This function is used to delete the created sidestep.